gulfpete
2004 FZ6N
I replaced the motor in my 2004 fz6n. thought some may benefit from what I learned. Thanks to Scott for his help.
The original motor had a bad knock when I bought it, got it very cheap. Turned out the camshaft had a slight wobble and the gear driving the clutch got very tight every 360 degrees.
This caused the casing to crack and the casing moving was the knock.
Anyway I got a 2006 fz6s motor off ebay - also very cheap, they said it was working well with low mileage and stuck it in the bike yesterday. The only thing i had to change was the cylinder head cover as the 06 model didn't have the outlets for the air cut off valve. I checked the timing and valve clearances while it was out, all spot on.
Got it fired up this morning and it had a hell bad rattle which turned out to be 2 things.
The roller bearings on the clutch basket were worn causing it to jump around. I found an old thread on here about a rattle and someone suggested the clutch, the only reason I checked it. I pulled the clutch assembly out of the old motor and stuck it in the new one, this can be done without taking the sump off, the bearing will slide out of the clutch then there is enough room to reach in behind and get the oil pump chain of the back of it. Same for installing.
Got that sorted and found another rattle witch was the pickup touching the pickup rotor. No idea why or how but swapped the cover for the one on the old motor and all sorted! Not a hint of rattle or knock or anything.
So I finally got to ride the bike today, well worth all the effort.
Pete
The original motor had a bad knock when I bought it, got it very cheap. Turned out the camshaft had a slight wobble and the gear driving the clutch got very tight every 360 degrees.
This caused the casing to crack and the casing moving was the knock.
Anyway I got a 2006 fz6s motor off ebay - also very cheap, they said it was working well with low mileage and stuck it in the bike yesterday. The only thing i had to change was the cylinder head cover as the 06 model didn't have the outlets for the air cut off valve. I checked the timing and valve clearances while it was out, all spot on.
Got it fired up this morning and it had a hell bad rattle which turned out to be 2 things.
The roller bearings on the clutch basket were worn causing it to jump around. I found an old thread on here about a rattle and someone suggested the clutch, the only reason I checked it. I pulled the clutch assembly out of the old motor and stuck it in the new one, this can be done without taking the sump off, the bearing will slide out of the clutch then there is enough room to reach in behind and get the oil pump chain of the back of it. Same for installing.
Got that sorted and found another rattle witch was the pickup touching the pickup rotor. No idea why or how but swapped the cover for the one on the old motor and all sorted! Not a hint of rattle or knock or anything.
So I finally got to ride the bike today, well worth all the effort.
Pete
